My Delta band saw project is coming together very well. The wheels and bearings are all on and the table is back on. Today I ordered one of those safety switches and really want to put it on the post that attaches the top to the bottom. The problem I have with it is that part is cast and I have no experience drilling cast. I am not afraid to try it but I wanted to run it past some of you first.

8 replies so far

i drill tables and cast iron for jigs and switches and fences all the timewhen needed

work my way up from a smaller hole firstto the larger sizestandard ‘jobber’ twist drills(the ones most common in stores as index sets)

just watch for ribbing and thick spots in the back of the castingso your washers and nuts don’t sit at a sloped angle

watch pushing to hard when they start to go thruas the bits get caught and can twist sidewayscast can be threaded toojust use the right drill recommended for the tap sizeand easy does it back it up to clear the tapand maybe a little 3 in 1 oil to lubricate

-- david - only thru kindness can this world be whole . If we don't succeed we run the risk of failure. Dan Quayle

“The post that attaches the top to the bottom”?Are you referring to the main frame that connects the top of the machine to the bottom of the machine?That is the most highly stressed component of the machine.Cast iron has very little strength in tension.It has mush more strength in compression.If you plan to drill a hole in the main column you would be wise to put the hole in the middle of the web where the stresses are neutral or in the side that is in compression. The side in compression would be the side nearest to the blade.

-- Michael: Hillary has a long list of accomplishments, though most DAs would refer to them as felonies.

as andy points outtapping screws should be fineyou might need to sacrifice a screw or twoas the ‘drill’ point is only so longand the treads may be compromised (worn down)by the time the tip is thruso just take that one outand insert another

easy does it

-- david - only thru kindness can this world be whole . If we don't succeed we run the risk of failure. Dan Quayle

A PO of my bandsaw mounted the switch box on the arm like you describe, but drilled the holes where the two cast pieces come together. A standard electrical box was attached using the two holes shown below.

Cheers,Brad

-- Brad in FL - To be old and wise, you must first be young and stupid

Along this same line I was wondering where some of you ran the wires too. I had originally thought I would run mine down the hollow casting but that would be almost impossible. So I am looking for ideas. Maybe I will just run the wire down the back of the casting in either conduit or just with wire clips of some kind.Charlie